8

8 - 105.07 e
6 4

7 7

15 16
2
1
13
Main drive Auxiliary drive
14
1 Main motor 9 Internal combustion engine
12
2 Flexible coupling with brake drum 10 Centrifugal clutch
3 Double shoe brake 11 11 Electrical auxiliary motor
5
4 Main gear box 12 Centrifugal clutch / brake
5 Lubricating oil system 10 13 Auxiliary gear box
6 Flexible coupling 14 Flange pump
7 Pinion gear 9
15 Free - wheel
8 Gearwheel guard 16 Flexible coupling

The drive components

Either single, double or triple reduc-
tion gearboxes are used, depending
on the torque to be transmitted.
These are the most common types
of drive for rotary kilns because
they have a high degree of efficiency
and long-term economical design.
One special feature of the gear drive, as a single drive with two pinions,
is that it can operate with only one main motor. This type of drive is often
used to increase productivity using the existing girth gear.
This variant, which was developed by KHD Humboldt Wedag, has two
positive advantages:
• no additional foundation is necessary for a second drive unit
• each pinion transmits precisely half of the torque

Nothing can shake them Feel free to create friction

The even, smooth operation of the
kiln and optimal contact pattern
with the pinion is achieved by
mounting the girth gear on the kiln
shell using tangential springs. The
centered action of the girth gear is
adjustable.
Gear drive (form-fit)
Function Transmission of loads via tyres and rollers,
transmission of torque via pinions and girth gear and rollers
Optimal separation of functions without
reciprocal influence
Design Components are optimised for the relevant
function
Efficiency Maximum degree of efficiency, minimum
wear and tear
Maintenance Ensure lubrication
Alternatively, it’s possible to transmit the drive torque from the rollers to
the tire. This type of drive is only suitable for two station kilns. The
characteristics of both types of drive are listed in the adjacent table.
Hydraulic drives – acting directly or via gears on the driven shaft – also
permit smooth kiln operation but are less efficient. This is why they are
also considerably less economical.
Compact and Efficient
Roller drive (friction-fit)
Transmission of loads and torque via tyres Rotary Kilns
Bearing and drive function in one unit means:
functional compromise
Additional drive forces requires stronger roller
bearings
Slipping and friction result in wear and tear to
tyres and rollers and impair efficiency
Ascertain friction values

KHD Humboldt Wedag ZAB Zementanlagenbau GmbH & Humboldt Wedag India Private Ltd. KHD Humboldt (Shanghai)
GmbH Industrietechnik & Service GmbH Espire Campus International Industries Ltd.
Colonia - Allee 3 Brauereistraße 13 A - 41, Mohan Co - op Estate, Office Beijing Guo Ji Da Sha 25 - A
51067 Cologne / Germany 06847 Dessau / Germany Mathura Road 19, Jiangou Menwai Dajie
Phone +49 221 6504 0 Phone +49 340 5029 0 New Delhi - 110044 / India Beijing / PR China
Phone +91 11 4210 1100 Phone +86 10 6500 4101

Humboldt Wedag, Inc.
400 Technology Parkway
Norcross GA 30092 / USA
Phone +1 770 810 7315
OOO KHD Humboldt Engineering
Mjasnizkaja ul., 24 / 7
Office 108
Moscow 10100 / Russia
Phone +7 495 9233480
KHD Humboldt Wedag Rep.
Iran Branch Office
3rd Floor, No. 244
Navak Building, Africa Avenue,
Tehran 15186 / I.R. Iran
Phone +98 21 8888 9880
Humboldt Wedag SA (Pty) Ltd.
36 Wankel Street, Jet Park
Boksburg, 1459 / South Africa
Phone +27 11 397 4660
www.khdhumboldt.com
 1
2

PYRORAPID ® kiln
1
2
3

3-station-kiln

It all started with a revolution

Kiln plants from KHD Humboldt Wedag are top of the line. One reason: highly efficient precalcining systems, All good things For example
which were developed by KHD Humboldt Wedag, revolutionizing the clinkering process. Rotary kilns no longer From time to time, special circum- • optimized kiln These kiln com-
have to function as calciners which mean that they can be substantially smaller in size. stances necessitate a kiln with a configuration ponents, essential
The advantage for customers is lower investment and operating costs. No wonder these systems quickly gained greater length to diameter ratio ensures even load for ensuring maximum
excellent reputations among our customers. which means that a three-station and force distribution availability, are furnished
kiln is needed. The three-station • the low shell stresses ensures low with high levels of safety and
This is what you can save
kiln from KHD Humboldt Wedag shell deformation and low con- service factors. Further information
In addition the PYRORAPID kiln offers:
® The main criteria for rotary kilns are
is a classic kiln which has been sumption of refractory material about these kiln components are on
• Investment costs approx. 15 % lower than three station kilns. high availability, considerable flexi-
thoroughly tried and tested over • the floating tire fastening system the following pages.
• The lower space requirements and lower weights lead to more bility and cost-effectiveness. They
the decades. Its proven standardi- ensures optimal load transmission
favorable construction costs. must also meet all process techno-
zed parts are also used in the to the rollers supported in double
• Mechanical overloading is impossible. This results in higher levels logy requirements for the clinkering
PYRORAPID ® kiln. Regular optimi- slide bearings
of operational reliability and lower maintenance costs. process. The KHD PYRORAPID ® ro-
zation of standardized parts leads • the large service factor of the kiln
• Lower consumption of refractory lining. tary kiln fulfills all of these require-
to even greater operational reliabi- drive ensures extremely flexible
• The reduced required power and lower radiation losses reduces ments. With two tire stations, length
lity and efficiency. The interaction plant operation
energy costs. to diameter ratio of approx. 11:1
of all components ensures the • the repeatedly proven kiln inlet
• The tire at the kiln discharge is to 12:1 and a statically defined be-
overall problem-free continuous and outlet seals ensure minimum
outside the sintering zone. aring arrangement, the PYRORAPID ®
operation of the kiln. false air infiltration.
kiln offers superior advantages over
Convincing arguments for the a two / three station kiln with a
benefit of our customers. greater length to diameter ratios.
Thermal plant with PYRORAPID ® kiln
 1
2

PYRORAPID ® kiln
1
2
3

3-station-kiln

It all started with a revolution

Kiln plants from KHD Humboldt Wedag are top of the line. One reason: highly efficient precalcining systems, All good things For example
which were developed by KHD Humboldt Wedag, revolutionizing the clinkering process. Rotary kilns no longer From time to time, special circum- • optimized kiln These kiln com-
have to function as calciners which mean that they can be substantially smaller in size. stances necessitate a kiln with a configuration ponents, essential
The advantage for customers is lower investment and operating costs. No wonder these systems quickly gained greater length to diameter ratio ensures even load for ensuring maximum
excellent reputations among our customers. which means that a three-station and force distribution availability, are furnished
kiln is needed. The three-station • the low shell stresses ensures low with high levels of safety and
This is what you can save
kiln from KHD Humboldt Wedag shell deformation and low con- service factors. Further information
In addition the PYRORAPID kiln offers:
® The main criteria for rotary kilns are
is a classic kiln which has been sumption of refractory material about these kiln components are on
• Investment costs approx. 15 % lower than three station kilns. high availability, considerable flexi-
thoroughly tried and tested over • the floating tire fastening system the following pages.
• The lower space requirements and lower weights lead to more bility and cost-effectiveness. They
the decades. Its proven standardi- ensures optimal load transmission
favorable construction costs. must also meet all process techno-
zed parts are also used in the to the rollers supported in double
• Mechanical overloading is impossible. This results in higher levels logy requirements for the clinkering
PYRORAPID ® kiln. Regular optimi- slide bearings
of operational reliability and lower maintenance costs. process. The KHD PYRORAPID ® ro-
zation of standardized parts leads • the large service factor of the kiln
• Lower consumption of refractory lining. tary kiln fulfills all of these require-
to even greater operational reliabi- drive ensures extremely flexible
• The reduced required power and lower radiation losses reduces ments. With two tire stations, length
lity and efficiency. The interaction plant operation
energy costs. to diameter ratio of approx. 11:1
of all components ensures the • the repeatedly proven kiln inlet
• The tire at the kiln discharge is to 12:1 and a statically defined be-
overall problem-free continuous and outlet seals ensure minimum
outside the sintering zone. aring arrangement, the PYRORAPID ®
operation of the kiln. false air infiltration.
kiln offers superior advantages over
Convincing arguments for the a two / three station kiln with a
benefit of our customers. greater length to diameter ratios.
Thermal plant with PYRORAPID ® kiln
It’s what’s inside that counts
In order to ensure a long service
life of the refractory lining, the kiln
ment. Depending on the layout,
there is a tertiary air take-off on
1 Inlet chamber
2 Brick retaining dish, air - cooled
3 Kiln tube
Both types of seals are designed to 4 Conical inlet ring
ensure a continuous seal despite 5 Scoop ring, air - cooled
1

shell is optimized for minimum
stress and deformation. The shell
plate thickness changes with corre-
sponding shell stresses, which
are determined from bending and
tangential shell stress loads. This
ensures optimal safety to material
either the front or back side of the
kiln hood. A large door opening
permits easy access to the kiln and
enables the use of portable convey-
ors for servicing.
We know what we’re
shifts in the position of the kiln due 6 Spring-loaded segment seal
7 Spring 2
to the influence of temperature and
8 Lever
longitudinal movement, as well as
any possible "deformations" to the
kiln shell. This also prevents false
air infiltration in the kiln.
6
The pressure forces 4

elasticity limits at operating tempe- talking about when it are adjustable

rature. Elastic shell deformations comes to seals on either type
remain within narrow limits. The high effi- of seal. 8

ciency and low

The kiln inlet
Put it all in wear rates of area with pneu-
3

Precalcined raw meal is fed from KHD kiln seals matically-opera-

ted seal ... ... or with spring-loaded segment seal.
the inlet chamber via the refractory make important 7
5
lined and air-cooled brick retaining contributions to
ring into the kiln. The simultane- economical kiln
ously rotating scoop ring safely operation. The
returns any hot meal backspill into proven spring-loa-
the inlet chamber. ded segmented seals,
which were developed by
What comes out KHD Humboldt Wedag, are fitted
The outlet end of the rotary kiln is to the kiln inlet and outlet. The pres-
protected by heat-resistant outlet sure elements, springs and levers,
segments. The air cooling of this rotate with the kiln, so they can be
3
large surface ensures long life of easily accessed at any time. KHD
the segments. Their bracket moun- rotary kilns can also be supplied
ting prevents flaring of the kiln with pneumatically operated seals. 1
shell. The kiln hood is supplied with Pressure is applied to the movable
monitoring and sampling openings, suspended sealing ring by a num-
connections for the burner and for ber of stationary mounted pneuma-
the control and measuring equip- tic cylinders.
2

4
The kiln outlet area
with spring-loaded
segment seal.

1 Outlet segments
2 Bracket
3 Brick retaining ring
4 Kiln tube
5 Cooling ring
6
6 Kiln hood 7
7 Spring-loaded segment seal
It’s what’s inside that counts
In order to ensure a long service
life of the refractory lining, the kiln
ment. Depending on the layout,
there is a tertiary air take-off on
1 Inlet chamber
2 Brick retaining dish, air - cooled
3 Kiln tube
Both types of seals are designed to 4 Conical inlet ring
ensure a continuous seal despite 5 Scoop ring, air - cooled
1

shell is optimized for minimum
stress and deformation. The shell
plate thickness changes with corre-
sponding shell stresses, which
are determined from bending and
tangential shell stress loads. This
ensures optimal safety to material
either the front or back side of the
kiln hood. A large door opening
permits easy access to the kiln and
enables the use of portable convey-
ors for servicing.
We know what we’re
shifts in the position of the kiln due 6 Spring-loaded segment seal
7 Spring 2
to the influence of temperature and
8 Lever
longitudinal movement, as well as
any possible "deformations" to the
kiln shell. This also prevents false
air infiltration in the kiln.
6
The pressure forces 4

elasticity limits at operating tempe- talking about when it are adjustable

rature. Elastic shell deformations comes to seals on either type
remain within narrow limits. The high effi- of seal. 8

ciency and low

The kiln inlet
Put it all in wear rates of area with pneu-
3

Precalcined raw meal is fed from KHD kiln seals matically-opera-

ted seal ... ... or with spring-loaded segment seal.
the inlet chamber via the refractory make important 7
5
lined and air-cooled brick retaining contributions to
ring into the kiln. The simultane- economical kiln
ously rotating scoop ring safely operation. The
returns any hot meal backspill into proven spring-loa-
the inlet chamber. ded segmented seals,
which were developed by
What comes out KHD Humboldt Wedag, are fitted
The outlet end of the rotary kiln is to the kiln inlet and outlet. The pres-
protected by heat-resistant outlet sure elements, springs and levers,
segments. The air cooling of this rotate with the kiln, so they can be
3
large surface ensures long life of easily accessed at any time. KHD
the segments. Their bracket moun- rotary kilns can also be supplied
ting prevents flaring of the kiln with pneumatically operated seals. 1
shell. The kiln hood is supplied with Pressure is applied to the movable
monitoring and sampling openings, suspended sealing ring by a num-
connections for the burner and for ber of stationary mounted pneuma-
the control and measuring equip- tic cylinders.
2

4
The kiln outlet area
with spring-loaded
segment seal.

1 Outlet segments
2 Bracket
3 Brick retaining ring
4 Kiln tube
5 Cooling ring
6
6 Kiln hood 7
7 Spring-loaded segment seal
 The roller bearing in indefinable changes to the ratio
of forces. This controlled absorption
of the axial forces is easy to recog-
nize at all times. It helps to preci-
sely adjust the bearing position and
to make any necessary corrections
during operation. One special ad-
vantage is that it offers the opportu-
nity, in the event of changed linear
expansion of the kiln shell, to return
the roller to an optimal position in
relation to the tire by way of the
linear adjustment of the bearing
block.
No fear of contact
In order to ensure uniform use of
the contact surfaces between tires
and supporting rollers, as well as
the girth gear and pinion, the axial
motion of the rotary kiln is hydrauli-
cally controlled. The hydraulic thrust
roller mechanism counteracts the
forces which are generated by
the slope of the kiln. It operates
automatically and is controlled by
non-contact measurement.

This is our drive

The drives for all kilns are designed for the reliable operation of the kiln under
any operating conditions. This means that even greater safety factors and
torque reserve, are installed for nominal operation. All drive components
are designed for the installed motor torque plus all safety factors and
not only for effective torque generated at nominal capacity.

The installed reserves and safety factors ensure the extremely

flexible operation of the kiln, including higher clinker throughput,
without overloading the drive.

Always up to date
The forged rollers and cast tires
have solid rectangular profiles.
They are manufactured without
relief or drilled holes to ensure that
no notch stresses or stress concen-
trations occur. The tires of the kiln
are designed according to Nies
The pressure’s on the hydraulic thrust roller mechanism
contact pattern between the tire
and rollers.
Based on a very simple principle
with nearly no weld seams:
the tyre fastening.
The sophisti-
station kiln during operation, the
system is equipped to do so. The
extremely robust and solid
construction of the be-
aring arrangement,
with double slide
bearing blocks
KHD Humboldt Wedag offers various types of drives for kilns opera-
tion, depending on the application. We differentiate between form-fit
drives (pinion / girth gear) for all kilns with two and three stations and
friction drives (roller / tire) for kilns with two stations.
Single drive with two pinions
This is where the power is
The drive units consist of the main and auxiliary drive. Variable speed AC or DC motors are used as drive
motors. The auxiliary drive is furnished with an electric motor and / or a combustion engine. In conjunction with
multi-stage or planetary gearboxes and elastic, practically maintenance-free couplings, the drives offer maximum
operational safety and outstanding efficiency.
The gear drive

for maximum ovality of 0.15 to 0.2 cated and which remain

percent of the nominal kiln diame- thousand- aligned, is desi-
ter. This guarantees the rigidity of fold proven gned to ensure
the tires. KHD roller that the roller
bearings stations have
One special feature is the constraint offer optimal a centering
free and low-maintenance tire faste- reliability. effect on the kiln.
ning system, which reliably transmits They are dimen- They absorb the re-
all loads via large contact surfaces sioned to ensure establishing forces of
at low surface pressure from the kiln they are not affected by the distorted kiln and do
shell to the tire. This also applies any types of load resulting from va- not deflect as flexible or moving
to the driving torque if the kiln is rious operating conditions. Howe- bearings would. The axial for-
powered by a friction drive. This ver, in the event that it is necessary ces are also effectively con-
connection also maintains a perfect to straighten a bent shell of a three- trolled and do not result
 The roller bearing in indefinable changes to the ratio
of forces. This controlled absorption
of the axial forces is easy to recog-
nize at all times. It helps to preci-
sely adjust the bearing position and
to make any necessary corrections
during operation. One special ad-
vantage is that it offers the opportu-
nity, in the event of changed linear
expansion of the kiln shell, to return
the roller to an optimal position in
relation to the tire by way of the
linear adjustment of the bearing
block.
No fear of contact
In order to ensure uniform use of
the contact surfaces between tires
and supporting rollers, as well as
the girth gear and pinion, the axial
motion of the rotary kiln is hydrauli-
cally controlled. The hydraulic thrust
roller mechanism counteracts the
forces which are generated by
the slope of the kiln. It operates
automatically and is controlled by
non-contact measurement.

This is our drive

The drives for all kilns are designed for the reliable operation of the kiln under
any operating conditions. This means that even greater safety factors and
torque reserve, are installed for nominal operation. All drive components
are designed for the installed motor torque plus all safety factors and
not only for effective torque generated at nominal capacity.

The installed reserves and safety factors ensure the extremely

flexible operation of the kiln, including higher clinker throughput,
without overloading the drive.

Always up to date
The forged rollers and cast tires
have solid rectangular profiles.
They are manufactured without
relief or drilled holes to ensure that
no notch stresses or stress concen-
trations occur. The tires of the kiln
are designed according to Nies
The pressure’s on the hydraulic thrust roller mechanism
contact pattern between the tire
and rollers.
Based on a very simple principle
with nearly no weld seams:
the tyre fastening.
The sophisti-
station kiln during operation, the
system is equipped to do so. The
extremely robust and solid
construction of the be-
aring arrangement,
with double slide
bearing blocks
KHD Humboldt Wedag offers various types of drives for kilns opera-
tion, depending on the application. We differentiate between form-fit
drives (pinion / girth gear) for all kilns with two and three stations and
friction drives (roller / tire) for kilns with two stations.
Single drive with two pinions
This is where the power is
The drive units consist of the main and auxiliary drive. Variable speed AC or DC motors are used as drive
motors. The auxiliary drive is furnished with an electric motor and / or a combustion engine. In conjunction with
multi-stage or planetary gearboxes and elastic, practically maintenance-free couplings, the drives offer maximum
operational safety and outstanding efficiency.
The gear drive

for maximum ovality of 0.15 to 0.2 cated and which remain

percent of the nominal kiln diame- thousand- aligned, is desi-
ter. This guarantees the rigidity of fold proven gned to ensure
the tires. KHD roller that the roller
bearings stations have
One special feature is the constraint offer optimal a centering
free and low-maintenance tire faste- reliability. effect on the kiln.
ning system, which reliably transmits They are dimen- They absorb the re-
all loads via large contact surfaces sioned to ensure establishing forces of
at low surface pressure from the kiln they are not affected by the distorted kiln and do
shell to the tire. This also applies any types of load resulting from va- not deflect as flexible or moving
to the driving torque if the kiln is rious operating conditions. Howe- bearings would. The axial for-
powered by a friction drive. This ver, in the event that it is necessary ces are also effectively con-
connection also maintains a perfect to straighten a bent shell of a three- trolled and do not result
 8
8 - 105.07 e
6 4

7 7

15 16
2
1
13
Main drive Auxiliary drive
14
1 Main motor 9 Internal combustion engine
12
2 Flexible coupling with brake drum 10 Centrifugal clutch
3 Double shoe brake 11 11 Electrical auxiliary motor
5
4 Main gear box 12 Centrifugal clutch / brake
5 Lubricating oil system 10 13 Auxiliary gear box
6 Flexible coupling 14 Flange pump
7 Pinion gear 9
15 Free - wheel
8 Gearwheel guard 16 Flexible coupling

The drive components

Either single, double or triple reduc-
tion gearboxes are used, depending
on the torque to be transmitted.
These are the most common types
of drive for rotary kilns because
they have a high degree of efficiency
and long-term economical design.
One special feature of the gear drive, as a single drive with two pinions,
is that it can operate with only one main motor. This type of drive is often
used to increase productivity using the existing girth gear.
This variant, which was developed by KHD Humboldt Wedag, has two
positive advantages:
• no additional foundation is necessary for a second drive unit
• each pinion transmits precisely half of the torque

Nothing can shake them Feel free to create friction

The even, smooth operation of the
kiln and optimal contact pattern
with the pinion is achieved by
mounting the girth gear on the kiln
shell using tangential springs. The
centered action of the girth gear is
adjustable.
Gear drive (form-fit)
Function Transmission of loads via tyres and rollers,
transmission of torque via pinions and girth gear and rollers
Optimal separation of functions without
reciprocal influence
Design Components are optimised for the relevant
function
Efficiency Maximum degree of efficiency, minimum
wear and tear
Maintenance Ensure lubrication
Alternatively, it’s possible to transmit the drive torque from the rollers to
the tire. This type of drive is only suitable for two station kilns. The
characteristics of both types of drive are listed in the adjacent table.
Hydraulic drives – acting directly or via gears on the driven shaft – also
permit smooth kiln operation but are less efficient. This is why they are
also considerably less economical.
Compact and Efficient
Roller drive (friction-fit)
Transmission of loads and torque via tyres Rotary Kilns
Bearing and drive function in one unit means:
functional compromise
Additional drive forces requires stronger roller
bearings
Slipping and friction result in wear and tear to
tyres and rollers and impair efficiency
Ascertain friction values

KHD Humboldt Wedag ZAB Zementanlagenbau GmbH & Humboldt Wedag India Private Ltd. KHD Humboldt (Shanghai)
GmbH Industrietechnik & Service GmbH Espire Campus International Industries Ltd.
Colonia - Allee 3 Brauereistraße 13 A - 41, Mohan Co - op Estate, Office Beijing Guo Ji Da Sha 25 - A
51067 Cologne / Germany 06847 Dessau / Germany Mathura Road 19, Jiangou Menwai Dajie
Phone +49 221 6504 0 Phone +49 340 5029 0 New Delhi - 110044 / India Beijing / PR China
Phone +91 11 4210 1100 Phone +86 10 6500 4101

Humboldt Wedag, Inc.
400 Technology Parkway
Norcross GA 30092 / USA
Phone +1 770 810 7315
OOO KHD Humboldt Engineering
Mjasnizkaja ul., 24 / 7
Office 108
Moscow 10100 / Russia
Phone +7 495 9233480
KHD Humboldt Wedag Rep.
Iran Branch Office
3rd Floor, No. 244
Navak Building, Africa Avenue,
Tehran 15186 / I.R. Iran
Phone +98 21 8888 9880
Humboldt Wedag SA (Pty) Ltd.
36 Wankel Street, Jet Park
Boksburg, 1459 / South Africa
Phone +27 11 397 4660
www.khdhumboldt.com